Method for manufacturing an optical element with a functional film

Abstract

Disclosed is a method for manufacturing an optical lens including the following successive steps: a step of providing an optical lens attached to a blocking piece; a step of laminating a functional film on a surface of the optical lens; a step of obtaining an assembly constituted by the blocking piece, the optical lens and the functional laminated film; a step of cutting the excess film directly on the assembly, so as to reduce the film shape; and a step of deblocking the optical lens with the film, and the blocking piece.

The invention claimed is: 
     
       1. A method for manufacturing an optical lens, the method comprising the following successive steps:
 a step of providing an optical lens attached to a blocking piece at a convex surface of the optical lens, the blocking piece acting as a receptacle to receive the optical lens; 
 a step of laminating a functional film on a concave surface of said optical lens opposite the convex surface to obtain a laminated lens surface; 
 a step of obtaining an assembly constituted by the blocking piece, the optical lens and the functional laminated film, the optical lens with the functional laminated film being fastened to the blocking piece by a bonding material; 
 a step of cutting a film excess directly on said assembly to reduce the film shape, the film excess comprising parts of the functional laminated film which extend beyond an edge of the optical lens and thus overhang the edge; and 
 a step of deblocking the optical lens with the functional laminated film, and the blocking piece, the deblocking step being carried out with at least a pressurized fluid jet configured to separate the optical lens with the functional laminated film from the bonding material. 
 
     
     
       2. The method according to  claim 1 , wherein the step of cutting the film excess allows that the entire film surface is completely adhered on the laminated lens surface, without any part of the film which overhangs the edge of the lens. 
     
     
       3. The method according to  claim 2 , wherein the step of cutting the film excess is determined to obtain a minimum radial distance in a plan view between an edge of the cut film and an edge of the laminated lens surface, the minimum radial distance being between 0.05 mm and 10 mm, the cut film edge being closer to a center of the lens than the laminated lens surface edge. 
     
     
       4. The method according to  claim 1 , wherein the step of cutting the film excess is carried out with one cutting element chosen from a sharp edge and a laser cutter. 
     
     
       5. The method according to  claim 1 , further comprising the following steps:
 a step of providing an assembly support; 
 a step of placing the assembly in said assembly support, so that the film constitutes the upper part of said assembly; 
 a step of providing an arm equipped with a cutting element in a fixed position relatively to a center of the assembly support, at least one element to be chosen from the arm and the assembly support being configured to rotate around a central axis of the assembly support; and 
 a step of rotating the at least one element relative to the central axis of the assembly support to allow the cutting element to cut the film excess. 
 
     
     
       6. The method according to  claim 1 , wherein the functional laminated film comprises a main film made of one of cellulose triacetate (TAC), polyethylene terephthalate (PET), polycarbonate (PC), polyvinyl alcohol (PVA), and cyclic olefin copolymer (COC). 
     
     
       7. The method according to  claim 1 , wherein the functional laminated film provides at least one feature to the lens chosen from one or more of a hard coat, an anti-reflective coating, a polarizing film, anti-shock properties, a tint, a mirror, a filter for specific wavelength, anti-smudge, anti-fog or antistatic properties, and self-healing or self-cleaning properties. 
     
     
       8. The method according to  claim 2 , wherein the step cutting the film excess is determined to obtain a minimum radial distance in a plan view between an edge of the cut film and an edge of the laminated lens surface, the minimum radial distance being between 0.05 mm and 5 mm, the cut film edge being closer to a center of the lens than the laminated lens surface edge. 
     
     
       9. The method according to  claim 2 , wherein the step of cutting the film excess is determined to obtain a minimum radial distance in a plan view between an edge of the cut film and an edge of the laminated lens surface, the minimum radial distance being between 1 mm and 3 mm, the cut film edge being closer to a center of the lens than the laminated lens surface edge. 
     
     
       10. The method according to  claim 2 , wherein the step of cutting the film excess is carried out with one cutting element chosen from a sharp edge and a laser cutter. 
     
     
       11. The method according to  claim 3 , wherein the step of cutting the film excess is carried out with one cutting element chosen from a sharp edge and a laser cutter.